Kiln for the manufacture of bloated clay products



E. M. WYATT Oct. 1l, 1932.

KILN FOR THE MANUFACTURE OF BLOATED 'CLAY PRODUCTS Filed Oct. 26. 1929 Zrzzfefz Zar Edwin M .Wgafh Q Q Q Q w wx Patented Oct. 11, 1932 UNEF 'raresv EDWIN IVI. WYATT, OF CLEVELAND, OHIO, ASSIGNOR, BY IVIESNE ASSIGNMENTS, TO AMERICAN FACE BRICK RESEARCH CORPORATION, A CORPORATION OF ILLINOIS KILN FOR THEMANUFACTURE OF BLOATED CLAY PRODUCTS Application filed october 26,1929. serial No. 402,601.

This invention relates to improvements in kilns fer the manufacture of bloated clay products. The kiln ofthe present invention is designed especially for use in the production of building units composed of bloated clay or other argillaceous material as set forth and described in co-pending application Serial No. 383,358, filed July 31, 1929, Cellular building material.

In the production of such a product, it is necessary to feed the raw material, in granular form, to a heat zone maintained at a temperature sufficient to lirst cause the searing over of the layer of material,.and thereafter to cause a bloating of the mass due to the evolution of gases, with the result that the bloated material possesses a cellular` structure caused by the expansion of gases within the fused and plastic mass. y

In the commercial production of such material, it is desirable to provide means for` continuously feeding granular raw material into the kiln in the form of a uniform layer, which underheat treatment will coalesce and expand into the form of a continuous column of Vbloated material, which is transported through the heat Zone and through an annealing chamber, and finally delivered to saws or other cutting devices which sever the continuous slab or column into units of the desired dimensions.

In the kiln of the present invention, provision is made for feeding the raw material to a traveling conveyor, which in effect constitutes the floor of the bloating chamber, and which of necessity must be formed of refractory material in order to withstand the high temperatures required, which ordinarily range from 2000 to 2300o F.vwithin the bloating chamber.

Provision is also made for initially leveling olf the granular material to provide a layer of uniform'thickness, and for rolling down or otherwise uniformly configuring the surface of the bloated slab of material while in the soft or plastic state, to maintain uniformity in thickness of the completed slab, or other desired configuration.

Gther objects and details will appear from a description of the invention, in conjunction with the accompanying drawing, wherein,-

Figure 1 is a longitudinal sectional view in ldiagrammatic form of a kiln embodying` the features of the present invention; and

Fig. 2 is a similar View illustrating Va modification of the same.

Referring to Figure 1, the kiln is built to provide a bloating chamber 10 having a top wall or roof 11 and a forward wall 12, the lower edge of which constitutes a cut off for leveling down the layer of argillaceous material which is fed from a hopper 13 to the lower edge of the wall 12. l l Y The floor of the bloating chamber is afforded by slabs 14 of refractory material, each slab being carriedhy atruck 15 provided with wheels 16 which travel upon a track 17. The slabs thus constitute. the deck plates of the respective trucks, and when the trucks are coupled together in train formation present a continuous floor or surface for the deposit of the material. The trucks are closely spaced to bring the slabs 14 into contacting relation, so that they constitute in effect a continuous movable Hoor 1wylllich travels at a slow speed through the The kiln also embodies a chamber 18 constituting an annealing oven, which is separated from the bloating chamber by a partition 19, the lower edge of which is suciently elevated above the traveling floor to permit the passage thereunder of the bloated 8'5 slab or column 20, but without affording free communication between' the bloating chamber and the annealing oven. As shown in Fig. 1, the central portion o f the annealing oven is vbroken away, but this oven should be of suflicient length, in relation to the speed of movement of the traveling conveyor, to afford time for the slow cooling of the product in order to toughen the same and avoid fracture due to rapid cooling. I In order to prevent the argillaceous material, when fused and sticky, from adhering te the surface ofthe traveling conveyor, a layer of sand or other parting material is deposited upon the floor at a point in advance 109 of the discharge end of the hopper 13, which sand or other parting material is fed from a hopper 21 located immediately adjacent to the hopper 13.

In order to more perfectly level down the top and sides ofthe bloated'material, a top roller 22. andside rollers 23 maybe provided,

tex-ture ofthe bloated column, or Where for other reasonsy exact uniformity infdimenf sions is not required. y

As shown,the rollers are located near the forward, end, ,of theajnnealing oven, Where theyzwillbe'somewhat protected from the intenseY Vheatw'ithin the bloating chamber, and Where they will act upon the top surface and edgesfofrthebloated, column whileV still in a somewhattsoft:or'plastic condition, although ifi desired'-l such, rollers `or other adequate meansmay. be locatedVv Within the bloatingV chamber'itself-1 i t Where-thefrollersare maintained in arelatively cool state by the passage of cool liquid Vorffgasesrit'` will `ordinarily 'fnot be necessary to; otherwise; provide against,adherence` of the: bloated material, but in case atendency to .adhere :fis vencountered it mayv be overcome .i by thesfeedi-ngof: a thin layer of sand or other parting; material upon ythepsurface ofl the bloated slab, in advance ofthe line; of. contactro theroller'or'rollers. As shovvn'such sand or the like may be fedfrom a hopper 24, whichi servesatosillustrategthefV principle involivedt. M Y

The 1 annealing. oven .at .its yrear end termi natese, inf.; endv wall 25,y under:Y whichV the completed column advances to one or more l longitudinal A.cutting-Wheels 26 and cross cutting wheels 2.7, which servetoy divide the completed columnf-into bricklikerunitsof the desiredt-dimeisions.v

Asshowrr, the kiln: ofthe present inventioirisfassociatedwith an inclined rotary kiln 28-of1aa well: known type of construction, Whichserves to :preheat the granular material underlv agitation and. discharge it, While still gramular: form, into the hopper 13, although it is-not essential in all `cases in the practice of the present invention that thematerialibe. preheated. f y The ftrucks, constituting:the-movable conveyor. of'thefkiln, after they VhaveY completed the transport ofthe column ofthe cutting Wheels;y may beunloadedand returned to the startingrpoint,either. individually or. in continuous train formation, the track being-properl'ycongured'to permit of the desiredmanipulationa Y From an inspection of Fig. l, it Will be observed that the material, While in granularV form, is leveled down to a layer of thedesired depth, and that as the layer progresses through the bloating chamber it will become expanded to two or Vmore times `the original. depth, the particles coalescing together into a continuous slab before the column emerges from the bloating chamber into the annealing oven.

The/speed o-ffy movement ofthe cars or trucks constituting the movable floor will be vregulated to"'afford adequate' time for the column to be fully bloated within the bloating chamber, but Without affording additionad time Whichmight resultinan excessive-liquefaction of the material and-'a breaking down' of the cellular structure. The` arrangement; is one Whichpermitsthefeedingspeedto be regulated in such away-as to bringthe material to theqdesired condition Withinthe-bloating chamber andto then introduce it tothe cooler atmosphere Within the annealing; oven, sothat it will become adequately annealed during-the period alloWed for its transport through the annealing oven, and finally reach` the cutting wheels in a: cooled and toughened condition.

Themoditication shown in Fig. 2 isquite similarfin principle, although diifering somewhat indetail. AIn thiscase, ,the kilnis provided Witha charging-chamber 28, a bloating vchamber 29, a rolling-,chamber 30, and an annealing chamber or4 oven 31. A strike off wall 32 separatesfthe charging chamber Vfrom.thelbloating chamber, and partition viously it, miOht/be fed from a preheater, .mi

rotary or otherwise, as heretofore described.

The material is fed onto an endless plate conveyor 39 composed of'slabs 40 of refractorymaterial, the ends of which preferably extend through'the sides of the kiln to exteriorly positioned chains l1 ycomposed of metallic links, whichl pass over exteriorly positioned sprocket. wheels 42 driven at a slow speed from any suitable source of power. By linkingl the refractory plates onto exteriorly positioned chains in the manner indicated,.the links will be relieved from the extremeheatwithin the interior of the kiln.

As the bloated column leaves the endless plate conveyor, itwill pass over and be supported upona transfer slide 43in the form of a hollow shoe, which may be Water cooled or otherwise cooled to prevent adherence of the slab or column of material. As the material enters the annealing chamber, it passes upon the upper turn of an endless metal conveyor 44 carried over rollers 45. S'ince'the temperature in the annealing chamber is much lower than that in the bloating chamber, itis feasible to use aimetal conveyor at this stage of the operation. After passing through the annealing chamber, the slab or column of material emerges and passes onto a stationary table 46, where it is severed by cutting Wheels into units of the desired size.

The material, as it passes from the bloating chamber into the rolling chamber is acted upon by a top roller 47 and side'rollers 48 similar to those heretofore described.V In the case of the plate conveyor shown in Fig. 2, the refractory plates constituting the conveyor surface are completely enclosed within `the structure of the kiln, which is desirable in'order to conserve heat and also to relieve the plates from the deteriorating effect due to frequent and violent changes in temperature. Furthermore, the structure of Fig. 2 shows the provision of a rolling chamber Vwhich lies intermediate the bloating` chamber and the annealing chamber, and serves to some extent to afford a Zone of intermediate temperature,`through Which the material passes before it enters the relatively cool atmosphere of the annealing chamber. However, it is obvious that the kiln in the form shown in Fig. l might be similarly provided with an intermediate chamber by simply adding a. partition wall in all respects similar to the wall of Fig. 2.

It will be obvious that the particular arrangement chosen Will depend somewhat upon local'conditions and the technique to be observed in the performance of the process.

Where it is desired to provide means foi` transporting the completed blocks from the furnace to a somewhat distant point, the truck or car arrangement shown in Fig. l may be deemed preferable, since the in dividual trucks, after passing the cutting Wheels, may be employed individually for transporting the completed blocks to the desired point. However, in doing so, the tops, or decl; slabs7 of refractory material would become cooled to a low temperature,

' so that heat is not conserved to the same bination ofatbloatingchamber, a chutefor delivering granularl earthy material at one end of the bloating chamber,a movable conveyor for receiving said material in the ,form of a continuous layer and transporting the same throughrthe bloating chamber, and t roller'means for acting pon the .surface of the material after bloating.v Y

2. In a kiln of the class described,the combination of a bloating chamber, a chute for delivering granular `earthy material at one end of the bloating chamber, a movable con veyor for 'receiw'n g said material in the form of a-continuous layer and transportingthe same through the bloating chamber, a `strike off wall located in proximate relation to the chute and above the conveyor for leveling the material on the conveyor. to the desired depth, and roller means for acting upon the surface of thematerial after bloating. v

v3. In a kiln of the class described, the combination of a bloating chamber, a chute for delivering granular earthy material at one end of the bloating chamber, `a movable conveyor for receiving said material Vin the form of a continuous layer and transporting the same through the' bloating chamber, 'a chute located in advance of the `rst named chute for delivering partingmaterialonto the surface ofthe conveyorto prevent adherence of theVv granular material, land roller means for acting" upon thevsurfaceof the material after bloating.l

i. in a. kan of the eiassae'scribed, the' combination of abloatinglchambena chute for Vdelivering granular earthy material at one end of thebloatingchamber, a movable conveyor for receiving` said material in the form of'a continuous layer andtransporting the same through thebloating chamber, a strike oif wall located inproximate relation to the chuteand above the conveyor for leveling the material-'on the conveyor to the desired'depth, a chute located in advance of the first named chute for delivering parting material onto the s'urfaceof'theconveyor to prevent 'adhesion of4 the. granular material, and roller means yfor acting upon the surface of the material after bloating.y

5. In a kiln ofthe class described, the combination of an enclosed bloating chamber and an enclosed annealing chamber, conveyor means furnishing a surface movable from a position outside of' and into and through the bloating chamber and through the annealing chamber, means for delivering-a continuous layer of granular-earthy material to thev conveyor prior to its entry into-the bloating chamber, and meansfor delivering a parting material to the surface of the conioo iio

izo

binationzof: a bloating chamber Yand an an-v nealing tchamber; conveyormeans Vfurnishing a. surface.- movable throught' the bloatingc chamber and: through the annealingcham-v ber, means fon deliveringr continuous layer. ofgranul'ar; earthy materialto the conveyor prior'to its entry into. the bloating chamber, meansfordeliveringpartingmaterial to the surface of thefconveyor. `prior/5tol the; deposit thereon o the granular: material, and cuttingdevicesiimproximaterelation; tothey conveyor.` means and locatedfbeyond the anneal-v ing.'4 chamberfon y'severa'm'gfthefmaterial into. units of thedesiredx dimensions.

.8. Inakiln of Ltheclass-described, the com` binatiomof avr bloatingchamben and-an annealing chamber, .a movable 5conveyor oper-f ablethrorughithef'bloatingl chamberfandpro` videdwithz surfacewslabs of'. refractory material, and Vmeans. forfdelivering; continuous layer'ofgrannlanearthymateria'l to .thesurface of the conveyorinzadvance.' offits en;-l try intor theebloating chamber:

9.v Irr azkln: off'tthe't class described, the combination of'aabloatingchamberf and an annealing;chamber," amovable conveyor.y opera-ble through the: bloatingf chamber and provided. Withf surface slabs: of refractoryr material, means forrdeliveringa` continuous layer. of granularl earthyfmaterial@toy they sur-v face of the-,conveyorin.` advance of=its entry into the` bloating` chamber, and-:means for deliver-ingipa-rting material to the surface of the-conveyor. in. advance ofthe deposit thereon of thefgranular material. K

10. In.akiln` of the class described,the combination offabloating chamber andan annealing chamber, .a-movable conveyor operable through the'bloating chamber and provided With surface slabs of'refractory material, means for delivering a continuous layer of granular earthy'material to the surface of'. the conveyor' in advanceof its entry into the bloating chamber,A and cutting de-I vices located beyond'the annealing chamber' and: adapted to sever the materiall into units of: the'desiredr dimensions.

11i In aAkiln'of'theclassdescribed, th

ycombinationv ofi abloating.y chamber and' an annealingcliamb'er, amevable' conveyor.v op:

nasa-e152 material, means for delivering-.a continuous. layer of granular earthy material toy thesurfy .faceaof the conveyor in advance of its entry into the,V bloating chamber, means for; der.

liveringparting. material .to -the'surface of' the conveyor in advance of the depositthereonk of the granular material, 'andcuttingf devices locatedbeyond the annealing.- chamber-and adapted to sever the. material into units of the desired dimensions.

12. Ina ln'ln of the class de'scribed,.they

combination of` a bloating chamber and an annealing chamber, a series of movable-,trucks provided With deck plates of refractory material.- and mounted to move4 through the bloatingchamber and through the annealing chamber in continuousprocession, and means for delivering granular earthyy ma,- ter-ial to the surface presented by the deck plates. prior tok the transport .of such ma terial intogthe bloating chamber.

13; In a kiln of theclass-described,the combination of a bloating chamber andan. annealingV chamber, a series of movable trucksprovided With deck` plates of refractory material and mounted tomove through' the bloating chambervand through the annealing chamber in continuous procession,

meansY for delivering granular; earthy ma` the transportl of vsuch material.- into the vbloat-Y ing chamber, and cutting devices located beyond the -annealingchamber and adapted to cut'v the material transported upon the.

deck plates into units of the desired dimensions.V 5 Y Y 15. In a kiln of the class described, lthe combination of a bloatingchamber 'and an annealing chamber, a series ofv movable trucks provided with deck plates of refractory material and mounted to movethrouglx the bloating chamber .and throughthe annealing` chamber in continuous procession, means for delivering granular earthy material to the surface presented byL the kdeck plates prior to the transport of such ma terial into the bloatingVY chamber, means for delivering parting` material-k to the surfaceV of suchdeck platesl prior to the. deposit thereon of the granular material, and cutting devices located beyond the annealing chamber and adapted to cut the material transported upon the deck plates into units of the desired dimensions.

16. In a kiln of the class described, the combination of an enclosed bloating chamber and an enclosed annealing chamber located in progressive alignment with one another, conveyor means furnishing a surface movable from a position outside of and into and through the bloating chamber and through the annealing chamber, and means for delivering a continuous layer of granular earthy material to the conveyor prior to its entry into the bloating chamber.

17. In a kiln of the class described, the combination of a bloating chamber, a chute for delivering granular earthy material at one end of the bloating chamber, a movable conveyor for receiving said material in the form of a continuous layer and transporting the same through the bloating chamber, and leveling means for smoothing down the surface of the material after bloating.

18. In a kiln of the class described, the combination of a bloating chamber, a chute for delivering granular earthy material at one end of the bloating chamber, a movable conveyor for receiving said material in the form of a continuous layer and transporting the same through the bloating chamber, a strike off Wall located in proximate relation to the chute and above the conveyor for leveling the material on the conveyor to the desired depth, and leveling, means for smoothing down the surface of the material after bloating.

19. In a kiln of the class described, the combination of a bloating chamber, a chute for delivering granular earthy material at one end of the bloating chamber, a movable conveyor for receiving said material in the form of a continuous layer and transporting the same through the bloating chamber, a chute located in advance of the first named chute for delivering parting material onto the surface of the conveyor to prevent adherence of the granular material, and leveling means for smoothing dovvn the surface of the material after bloating.

In Witness that I claim the foregoing I have hereunto subscribed my name this 16th day of October, 1929.

EDWIN M. WYATT. 

